Means for forming wire terminals



Dec. 16, 1924. v 1,519,550

C. POZGAY MEANS FOR FORMING WIRE TERMINALS 'Filed Feb, 14, 1924 INVENTOR0/4151 fjazmy i3 A ITOI RNEY Patented Dec. 16, 1924.

UNITED STATES CARL POZGAY, OF JAMAICA, NEW YORK.

MEANS FOR FORMING WIRE TERMINALS.

App1ication filed. February 14, 1924. Serial No. 692,623.

To all whom it may concern;

Be it known that I, CARL PozcAY, a citizen of the United States, andresident of Jamaica, in the county of Queens and State of New York, haveinvented certain new and useful Means for Forming Wire Terminals, ofwhich the following is a specification.

This invention relates to improvements in pincers and more especiallytov terminal forming pincers.

Primarily my purpose is to provide a tool which will successfully engagethe end of an electrical wire and form a terminal therein withoutweakening or breaking the conductor.

It is also my purpose to furnish such a device in a form convenientlyhandled and adapted to work in positions not accessible to the toolsordinarily employed for such purposes.

The especial object of my invention is to supply a tool which may beoperated within the narrow spaces available about electrical apparatusand which will form the necessary wire terminals in their correctpositions, after the wire has been cut to the required length.

Electrical wiring for light and power service is now almost universallycontained within conduits terminating in boxes, which are usuallyembedded in the wall or ceiling. Narrow constricted places areunavoidable, there is seldom room for surplus wire length, especially atpoints where a lamp socket or switch must also fit into the conduit box.The wires must therefore be cut barely long enough to reach, andencircle, the terminals of the electrical device. The wireman is thenconfronted with the problem of bending the wire about the terminal;often his ordinary wire pliers will not even reach the wire end.Manipulation is practically impossible, the result is the wire is merelyclamped" beneath one side of the terminal screw head and the firstvibration loosens it. Often, in seeking to make a secure connection, thewire end is cut by the tools used and breaks off. The wire havingpreviously been cut to minimum length (to get it into the box) thisbreakage sometimes involves hours of labor and the rewiring of an entiresection of conduit. My device provides for the avoidance of suchbreakage, for the correct forming of a wire terminal, for reaching thewire end in the most inaccessible places, and for reducing the labor andskill required. The herein disclosed device is especially adapted foruse in making the connections of radio apparatus, where the space isvery limited, the parts are fragile and the liability to damage ofvaluable apparatus by a chance blow, very great. Here, even more than inpower and light wiring, connections of low resistance and absolutesecurity are essential. Much of this work must also be accomplished bypersons unskilled in electrical work and unfamiliar with the use oftools. Naturally, breakage of wiring and like troubles are even moreliable to occur than with the experienced wireman, whose skill in theuse of his tools somewhat compensates for their lacking features. Myinvention provides a tool which forms the wire end to the best terminalform regardless of the skill of the operator and which prevents allpossibility of cutting or nicking the wire and causing breakage, whilethe reduced amount of skill required enables the amateur to work withsureness among the most easily breakable devices.

The pliers, which have been chosen for purposes of illustration, areshown in the accompanying drawings and the appended description willshow one method of accomplishment of the above stated objects.

Figure 1 is an elevation of one form of pincers embodying my invention.

Fig. 2 shows the end of the pinc-ers shown in. Fig. 1 on an enlargedscale.

Fig. 3 is a top view of the jaw portions of a modified form of myinvention.

Fig. 4 shows in elevation the device shown in Fig. 3.

Fig. 5 is a top view of the jaw portions of a further modification ofembodiment.

Fig. 6 shows in elevation the device illustrated in Fig. 5.

Fig. 7 illustrates a form of wire terminal produced by use of my device.

Fig. 8 serves to show an application of my device.

That form of my device illustrated in Fig. 1 shows pliers having theusual handles 9, hinge 10, cutters 12 and jaws 1i and 1.6.

To furnish a preferred means for accomplishing my invention, I form adie 20 upon the jaw 14 and a punch 22 upon jaw 16. Punch 22 issubstantially cylindrical and the die 20 is substantially tubular inoutline.

The inner surface 23 of the die is formed to substantially the externaloutline of the wire terminal to be formed, While the Outer surface ofthe punch 22 is shaped to substantially the internal outline of thedesired wire terminal. The punch and die are preferably so mounted uponthe plier jaws that when said jaws limit faces or stop portions 14 arein contact the difference between the radius of the outer punch surface(indicated as R in Fig. 2) and the radius of the inner die surface 23(indicated by R) equals the diameter of the wire 25, which is to bebent. Die 20 then preferably provides an inner surface 23 as an arc of atrue circle about the centre of punch 22.

The ends of die 20 are preferably rounded as at 24 to prevent possiblenicking of the wire surface and to conform to the surface of the reversebend 27 of wire 25 where it leaves the terminal loop.

Since the jaws 14 and 16 are together when R minus R equals the diameterof wire 25, manifestly the die 20 and punch 22 can never be broughtcloser together and regardless of pressure, wire 25 will not beflattened, while the length of die which I provide prevents necessity ofthe reverse bend 27 being made by twisting the pliers about, the singlepressure referred to above forms one half the terminal loop and thereverse bend 27 simultaneously.

The manner of forming a terminal is best seen from an inspection of Fig.7 wherein the base of an electrical device supports a connection strap38 having an opening 40 for the reception of a wire clamping screw (notshown). The wire 25 is first positioned straight over the opening 40 (asindicated by the dotted lines 42) die 20 and punch 22 are positionedupon either side of the wire and pressureapplied. Part of the terminalloop is thus formed, the extra wire ma terial projecting as indicated bythe dotted lines 44. Wire 25 is then released, the positions of die 20and punch 22 reversed by turning over the pliers, and the punch and dieengaged with the projecting wire material. A second pressure then formsanother part of the terminal loops, surplus wire being brought to lieparallel with wire 25 as indicated at 46. The screw may then be placedin opening 40 and upon tightening the same a perfect electricalconnection will be madesince the wire clamping screw is completelyencircled by the wire.

It should be said however, that it is seldom possible to position thepliers directly above the point where the wire terminal is to be formeddue to obstructing apparatus or wiring. I have therefore provided forforming my cooperating punch and die at right angles to the jaws 14 and16, (see Figs. 3 and 4), thereby permitting the plier handles 9 to liesubstantially parallel to wire 25 when in the position shown in Figs. 2and 7.

Nor is it always possible that the plier handles lie parallel with thewire 25 often the only available angle of approach is that lying betweenthe horizontal and the vertical (respective to the plane of the terminalloops required). This condition I provide for by forming the die 20 andpunch 22 with their axis at substantially 45 degrees to the jaws 14 and16 as shown in Figs. 5 and 6.

The convenience of this forty-five degree arrangement of die and punchis illustrated in Fig. 8, in which figure represents a portion of astandard conduit wiring box. As will be understood by those familiarwith such wiring, box 60' is commonly embedded in the wall 62 with itsfront flange 64 pro.- j ecting over the edge of the box opening for thesecuring of front plates andthe, like. The base 35 of an electricaldevice set within box 60 is provided with a connectionistrip 38 thecombination being similar to that described for Fig. 7 with theexception that flange 64 effectually prevents access from the top whilethe box wall prevents access from the side. That form of my inventionshown in Figs. 5 and 6 is most conveniently employed as indicated, itwill be noted that neither the box wall nor the flange 64 interfere withforming a satisfactory terminal in the correct place over connectionstrip 38*. 64 might equally Well illustrate the position of a detectorbulb whenmy device is used in wireless apparatus assembly. It will bemanifest that such a bulb would be safe from destruction, since thepliers jaws and operators hand are well removed therefrom.

Figure 8 will also serve to illustrate the extremely close quarters inthe average conduit box, the truth of the foregoing statement asbreakage of the wire end often necessitating complete rewiring of aconduit section will be self-evident.

Manifestly many changes may be made in the embodiment of my inventionand in the application thereof While still accomplishing beneficialimprovements over. the prior art. As an instance of such change, anyform of pincers may replace the pliers shown for purposes ofillustration, and such form may be of the tweezer type, of the toggletype, or of one of the many other types well known to those skilled inthe art; Such changes are believed to be well within the spirit of myinvention and the scope of the appended claim.

hat I claim is:

A wire bending tool comprising a pair of pliers having jaws pivotallyconnected'and extending forwardly from the pivotal point, said jawshaving substantially flat coacting faces limiting their movement in onedirection by closing on each other, a cylindrical pin extending from oneof said jaws and having its longitudinal axis in the plane of said faceof said jaw, and a cylindrical die carried by the other jaw and havingits longitudinal aXis in the plane of the last mentioned jaw, said axescoinciding upon the jaws being closed, said die having an internalradius greater than the external radius of the pin whereby space forwire is left between the pin and die upon the aws being closed to enga eeach other.

Signed at New Y ork, in the county of New York and State of New Yorkthis 11th day of February A. D. 1924.

CARL POZGAY.

